Satellite servicing

ABSTRACT

This invention relates to an improved satellite servicing system. The improvements include improvements in payload distribution in the cargo bay of the Shuttle Orbiter and improvements in the location of the targets required for positioning end effectors with respect to the component which they are to engage. In the improved satellite servicing system, the remote manipulator system which is normally used for the purpose of capturing and deploying satellites is also used for servicing the satellites when captured and secured for servicing. An improved payload distribution system is provided in the cargo bay which permits optimum utilization of the cargo bay by primary payload units by providing for the location of secondary payload units at any convenient position of opportunity along the length of the cargo bay. In the improved target system, targets are mounted at a site which is remote from the complementary component which is to be engaged by the end effector carried by the manipulator arm such that the target does not permanently obscure the line of vision of the television camera which is mounted on the remote manipulator.

This is a division of application Ser. No. 054,,829, filed July 3, 1979, now U.S. Pat. No. 4,273,305.

BACKGROUND OF INVENTION

This invention relates to The Space Shuttle Orbiter. In particular, this invention relates to an improved satellite servicing system and improvements in the payload distribution in the cargo bay of a Space Shuttle Orbiter.

A satellite servicing system is described in U.S. Pat. No. 4,079,904, dated Mar. 21, 1978. In this known system, the remote manipulator arm which is used for the purposes of capturing and deploying an orbiting satellite is not used for the purposes of exchanging modules between the satellite and the replacement module assembly. The module exchange mechanism of this prior patent is capable of operating independently of the remote manipulator arm. This mechanism has previously been used in conjunction with a relatively large replacement module storage magazine. The module exchange mechanism and replacement module storage magazine are generally housed in the aft section of the cargo bay so that the forward section is available for using in stowing a primary payload assembly such as a satellite, an orbiter probe or the like. The replacement module storage magazine and the module exchange mechanism previously proposed occupied a substantial portion of the cargo bay and thus effectively reduced the payload capacity of the cargo bay. To provide for the most efficient use of the orbiter, it is important to maximize the payload capacity of the cargo bay and to minimize the portion of the cargo bay utilized for the stowing of secondary payload items such as replacement modules and the Module Exchange mechanism for effecting transfer of replacement modules between the replacement module storage device and the satellite which is to be serviced.

It is an object of the present invention to provide an improved satellite servicing system for an orbiter in which the Remote Manipulator System which is normally used for the purpose of capturing and deploying satellites is also used in the servicing of satellites when captured and secured for servicing.

A further object of the present invention is to provide an improved payload distribution system in a cargo bay of an orbiter which permits the optimum utilization of the cargo bay by primary payload units by providing for the location of secondary payload units at a convenient position of opportunity along the length of the cargo bay.

A further object of the present invention is to provide an improved target system for use in a remote manipulator system wherein the target is mounted at a site which is remote from the complementary component which is engaged by the end effector such that the target does not permanently obscure the line of vision of the television camera when the complementary component is removed from its support structure.

SUMMARY OF INVENTION

According to one aspect of the present invention there is provided in a space orbiter having a cargo bay formed therein which has a longitudinal extent in a first direction, said orbiter being adapted to open to provide access to the cargo bay through an access passage extending along said cargo bay in said first direction, an improved satellite servicing system comprising a remote manipulator system which includes a remote manipulator arm having a first end secured to the orbiter and a free end which may be moved in response to manipulation of the arm to be positioned at any required point with a predetermined operational range extending within and without said cargo bay for use in the capturing, deploying and servicing of satellites and the like, a combined satellite service and replacement module support assembly mounted in said cargo bay within said operational range of said arm, said support assembly comprising a support frame mounted in and extending transversely of said cargo bay within said operational range of said arm, a plurality of replacement modules releasably mounted on said support frame in a side-by-side generally planar array, said replacement modules being accessible to and releasable by the free end of said manipulator arm, a satellite servicing platform on said frame, said platform being adapted to support a satellite in a satellite servicing position within said operational range of said manipulator arm whereby the manipulator assembly may be operated to effect an interchange of modules between a satellite located on said platform and modules located on said support assembly.

According to a further aspect of the present invention, there is provided a space orbiter having a cargo bay formed therein which has a longitudinal extent in a first direction, an improved payload distribution system comprising a remote manipulator assembly operable to perform manipulating functions within a predetermined range along the longitudinal extent of the cargo bay, mounting means in said cargo bay and located within at least said operational range of said remote manipulator assembly adapted to operably locate payload assemblies at a plurality of positions along the length of said cargo bay, a first primary payload assembly located in said cargo bay and mounted on said mounting means at a convenient location along the length of said cargo bay to provide a free length of cargo bay at a position of opportunity along the length of said cargo bay, a secondary payload assembly disposed in said free length of said cargo bay and mounted on said mounting means, thereby to permit optimum utilization of said cargo bay.

According to a further aspect of the present invention, there is provided in a remote manipulator system in which a television camera is mounted at the free end of a manipulator arm to relay a target image to a monitor having image alignment markings thereon, the manipulator arm having an end effector located at the free end thereof for use in mounting and releasing a complementary component with respect to a support structure, the improvement of a target mounted at a site remote from said complementary component on the direct line of vision of said camera when said end effector is axially aligned with said complementary component and said complementary component is mounted on said support structure, said target being proportioned such that its image viewed at the monitor is coextensive with the image alignment markings of said monitor when said end effector is operably positioned to mount or release said complementary component with respect to its associated support structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a pictorial view of a space orbiter in which the cargo bay is open to illustrate the location of a combined satellite service and replacement module support assembly and a plurality of alternate positions thereof;

FIG. 2 is a pictorial view of the combined satellite service and replacement module support assembly of FIG. 1 in enlarged detail;

FIG. 3 is a front view of the combined satellite service and replacement module support assembly with the modules and their associated latching frames removed;

FIG. 4 is a view similar to FIG. 3 illustrating the assembly of FIG. 3 with the module latch frames mounted thereon;

FIG. 5 is a side view of an orbiter illustrating the location of the combined satellite service and replacement module support assembly in a position of opportunity in the cargo bay;

FIG. 6 is a side view of an orbiter similar to FIG. 5 illustrating the location of the combined satellite service and replacement module support assembly in a further position of opportunity in the cargo bay;

FIG. 7 is a side view of the free end of the manipulator arm showing the manipulator arm end effector and a module interchange end effector mounted thereon with a television camera mounted on the end effector in alignment with a number of potential target mounting sites; and

FIG. 8 is a front view of a television monitor illustrating the target alignment technique.

DETAILED DESCRIPTION OF THE INVENTION

With reference to the drawings, reference numeral 10 refers generally to a Space Shuttle Orbiter. The orbiter has a cargo bay generally identified by the reference numeral 12 which, in FIG. 1, is shown in the open position. The cargo bay 12 extends longitudinally of the Space Shuttle Orbiter and has its forward end disposed adjacent the crew compartment of the Shuttle Orbiter which is located in the forward end of the Space Shuttle Orbiter. The Space Shuttle Orbiter has longitudinally extending doors 14 and 16 which are openable to provide access to the cargo bay through an access passage extending along the cargo bay in the direction of its longitudinal extent. The doors 16 and 14 are powered for movement between the open position illustrated in FIG. 1 and the closed position totally enclosing the cargo bay.

As in previously proposed cargo bay constructions, a plurality of trunnion fittings 18 are provided at spaced intervals, generally eighteen inches, along the length of the cargo bay. The support trunnion fittings 18 extend along substantially the full length of the cargo bay and provide payload support means at spaced intervals along the length of the cargo bay for supporting payload units therein.

The Space Shuttle Orbiter 10 is provided with a remote manipulator assembly which includes a remote manipulator arm 20 which has one end mounted by means of a shoulder joint 22 at a predetermined position along the length of one wall of the cargo bay. The arm 20 has a remote manipulator end effector 26 connected to the free end thereof by a wrist joint 24. The remote manipulator end effector 26 has a television camera 27 mounted adjacent thereto. The direct line of vision of the camera 26 is arranged to extend from the focal point of the camera along an axis parallel to the longitudinal axis of the end effector 26. The end effector 26 may be in the form of a grappling device similar to that described in U.S. Pat. No. 4,105,241, Mee et al, dated Aug. 18, 1978. The end effector 26 may be operably secured with respect to a grapple fixture mounted on a satellite or on any one of a number of tools such as module release end effectors. The manipulator arm 20 is capable of operating over a predetermined operational range B extending within the cargo bay and it is capable of operating without the cargo bay for the purposes of capturing or deploying an orbiting satellite generally identified by the reference numeral 28. The overall length A of the cargo bay may be of the order of about sixty feet with the operational range B of the manipulator arm operating in conjunction with the assembly 30 being of the order of about forty feet.

A combined satellite service and replacement module support assembly constructed in accordance with the embodiment of the present invention is generally identified by the reference numeral 30. The assembly 30 may be located at any required position of opportunity along the length of the operational range B, by selecting the most convenient trunnion support 18 for use in supporting the assembly 30. By reason of the fact that the assembly 30 may be positioned on any one of the trunnion supports 18, the most convenient trunnion support may be selected to enable the assembly 30 to be located at substantially any required location along the length of the cargo bay. As a result, it is possible to plan the distribution of the primary load based upon the total cargo bay length A and thereafter to locate the assembly 30 at any convenient position of opportunity within the operational range B. It will be understood that the primary payload units are supported by trunnion frames which are in turn mounted on the most conveniently located trunnion fitting 18 to achieve the required load distribution. Thus, as shown in FIG. 5 of the drawings, the assembly 30 may be located between primary payloads 32 and 34. The configuration illustrated in FIG. 5 is a configuration which might conveniently be used in Flight No. 13 of the current shuttle orbiter flight manifest in which the assembly 30 is located between the primary payload unit 32 which is the SSUS-A and primary payload unit 34 which is INTESLAT V.

FIG. 6 illustrates a different payload distribution in which the assembly 30 is located in the aft section of the cargo bay and the primary payload unit 36 is located in the forward section of the cargo bay. This diagram illustrates a possible payload distribution for use in Flight No. 23 in which the primary payload unit is a Jupiter Orbiter Probe.

It will be understood that the payload distribution system of the present invention is equally applicable to any other space shuttle orbiter flight.

The combined satellite service and replacement module assembly 30 is illustrated in detail in FIGS. 2, 3 and 4 of the drawings to which reference will now be made.

The assembly 30 consists of a support frame generally identified by the reference numeral 40, a satellite servicing platform generally identified by the numeral 42 and a plurality of replacement modules of which two types are identified by the reference numerals 44 and 46, respectively.

The support frame 40 consists of a perimeter member 48 which is proportioned so as to extend in close proximity to the sides of the cargo bay when located therein. The perimeter member 48 has trunnions 50 projecting outwardly therefrom which are adapted to engage the trunnion support frame 18 to support the assembly 30 in a position extending transversely of the longitudinal extent of the cargo bay. Mounting frame members 52, 54 and 56 extend transversely across the perimeter member 50 and are arranged in a spaced parallel relationship one above the other. A plurality of mounting passages 58 are located at spaced intervals along the length of each of the mounting frame members 52, 54, 56. Latching frame members 60 and 62 extend between and are secured to adjacent frame mounting members and are selectively positioned to the proportions required for use in supporting the replacement modules 44 and 46, respectively, by use of the appropriate mounting passages 58, the latching frame members 60 and 62 being bolted to the mounting frame members through the mounting passages 58 and corresponding mounting passages at each end of the latching frame members.

The latching mechanism used for releasably securing the replacement modules with respect to the assembly 30 may be of any convenient latching structure. In one form, the latching mechanism may include latching probe assemblies, latching barrel assemblies and latch operated mechanisms of the type described in U.S. Pat. No. 4,078,904. The latching probes are secured with respect to the latching frame members and remain attached to the support assembly 40 after the module has been released. The latching barrels are carried by the replacement modules and the latch operator is an end effector located at the free end of the manipulator arm assembly. In the embodiment illustrated in FIG. 4 of the drawings, latching probes 66 are mounted on the latch frame members 60 and identical latching probe members 68 are mounted on the latching frame members 62. The latching barrels 70 are secured with respect to the replacement modules 44 and identical latching barrels 72 are secured with respect to the replacement module 46. The latch operator mechanism is incorporated in the end effector 74 which, during assent and descent of the Space Shuttle, may be parked on a latching probe 76 of the type previously described which is located on a support plate 75 (FIG. 2). A similar parking latching probe 78 is mounted on the main frame 48 on the opposite side of the satellite support platform 42. Parking latching probe 78 may be used to provide a temporary support for modules which are removed from the satellite which is being serviced so that the manipulator arm may be freed to move a replacement module from the replacement module storage assembly direct to the satellite.

The satellite service platform 42 consists of a turntable, generally identified by the reference numeral 80 which includes a stationary component 82 which is secured with respect to the transversely extending support frame member 86 and a rotating member 88 which is rotatably driven by a suitable drive mechanism (not shown). The rotating member 88 has three arms 92 projecting outwardly therefrom. One or more of the arms 92 may be hingedly connected by means of hinges 94 to the rotating member. The hinges 94 permit the satellite docking platform to assume a compact configuration when not in use such that the overall length thereof is no greater than the length C. The legs or arms of the turntable assembly may also be jettisonable if required.

Visual alignment targets are provided to permit the crew to operably position the end effector 26 or the end effector 26 and an associated end effector 74 with respect to a complementary component such as the barrel 70 which is to be manipulated thereby. An example of one target is the target 100 which is associated with the end effector 74 (FIG. 2). It will be noted that the target mounting site of the target 100 is the support frame assembly 40 and not the end effector 74. Thus, the target 100 is located in a plane which is spaced rearwardly from the interface which will be formed between the end effector 26 and the end effector 74 when operably connected to one another. Similarly, the target 100a is mounted on the support frame 40 in a plane spaced rearwardly from the interface to be formed between the support probe 78 and a replacement module temporarily parked thereon. In a like manner a target 100b is mounted at a site on the support frame 40 so as to be associated with each latching barrel 70.

As shown in FIG. 7 of the drawings, the television camera 27 has a direct line of vision extending along the axis 110 in a plane parallel to the longitudinal axis 112 of the remote manipulator end effector 26 on which the camera is mounted.

A monitor 114 is located in the crew cabin for use by the crew in monitoring the pictures taken by the camera 27. The monitor 114 has image alignment markings 116 applied directly to the viewing screen thereof. The visual alignment targets are arranged and proportioned so as to be aligned with and coextensive with the image alignment markings when the remote manipulator system is operably positioned with respect to the complementary component associated with the selected visual alignment target. Image outlines 124 and 126 illustrate the progressive increase in size of the target image as the camera advances toward the target.

As shown in FIG. 7 of the drawings, the position of the focal point 118 of the camera is fixed with respect to the plane 120 which is located at the interface formed between the remote manipulator end effector 26 and the module interchange end effector 76 and with respect to the second plane 122 which is located at the interface of the module interchange end effector 76 and its complementary component. Thus, the size of the target required to fully fill the image alignment markings will vary in direct proportion to the distance at which the target is sighted from the focal point of the camera. It follows that it is not necessary to locate the targets in the plane of the various interfaces provided the targets are located on the direct line of vision of the camera and are proportioned to provide an image which is coextensive with the image alignment markings 116 when the required interface connection is established in use. This is an important feature because it permits the visual sight targets to be located at any convenient site remote from and rearwardly from the component which is to be engaged by the manipulator arm in use. Thus, for example, when the end effector 26 is used to engage the end effector 76 the target 100 is used to achieve the required positioning of the manipulator arm assembly. The target 100 remains with the support structure with the result that when the end effector 76 is removed from its parking probe, the direct line of vision of the television camera will not be obstructed by the end effector 76 and the camera may be used to achieve subsequent positioning of the end effector 76 with respect to a complementary module exchange latching barrel.

In use, it is important to achieve maximum utilization of the cargo bay space in order to provide a maximum payload capacity for primary payload units. This desirable objective is achieved in accordance with the present invention by reason of the fact that it is possible to plan the location of one or more primary payload units at appropriate positions in the cargo bay and to locate the secondary payload unit in the form of a replacement module support assembly at any convenient position of opportunity provided by the distribution of the primary payload unit. Having selected the appropriate primary payload and secondary payload distribution, the primary payload items and secondary payload units are located as planned in the cargo bay. The space orbiter may then be launched and made operational to effect deployment of its cargo. The space orbiter may also be manoeuvered to close proximity with an orbiting satellite or the like. The remote manipulator assembly may then be activated to extend the manipulator arm so that its end effector with the aid of suitable visual targets engages a grapple device conveniently located on the satellite. The manipulator arm may then be manipulated to locate the satellite on the satellite servicing platform 42. The satellite platform 42 may be rotated so that the modules 44 are directed in the general direction of the crew compartment of the space orbiter so as to be visible through observation windows which permit viewing from the crew compartment into the cargo bay. The crew then maneuvers the remote manipulator system to pick up the module exchange end effector 74 using the visual target 100. The manipulator arm with the module exchange end effector 74 located thereon is maneuvered to engage the module release latch mechanisms to release a module 44 a mounted in the satellite. The module 44a is then transferred by the manipulator arm to the parking latch 78. A replacement module 44a is then removed from the replacement module support assembly and located in the compartment which was vacated by the module 44a. Thereafter the module 44a is removed from the parking latch 78 and mounted on support frame at the position vacated by the replacement modules. This process may be repeated until all of the required modules have been interchanged.

As shown in FIG. 2 of the drawings and as previously indicated, one of the replacement modules may be in the form of a propulsion module 46. In order to support the propulsion module in the position to facilitate the manipulation thereof, a special purpose support frame is required. The special purpose support frame is readily mounted on the previously described main support frame and serves to locate the replacement modules in a position in which the latching mechanism are readily accessible to the end effector.

It will be noted that the combined satellite service and replacement modules support assembly of the present invention can be positioned in the cargo bay with the replacement modules mounted on the base thereof which is directed toward the forward end of the cargo bay with the result that the modules and their supporting latch mechanisms are readily visible from the cargo bay. This permits the crew operator to observe the manipulations of the remote manipulator mechanism as it effects latching, unlatching and transfer of the modules between the satellite service and replacement modules support assembly and a satellite mounted on the support platform in use.

Various modifications of the structure of the present invention will be apparent to those skilled in the art without departing from the scope of the invention. For example, the distribution and proportions in the various modules which are mounted on the replacement modules support may vary as required in use. This may be achieved by adjusting the position of the mounting frame members or the latching frame members of the module support assembly.

As previously indicated, the latching mechanism used for releasably securing the replacement modules and the end effector used in conjunction therewith may be of any convenient latching structure. In one such proposal, a threaded latching pin is mounted on the latching frame members and projects outwardly therefrom. A latching nut is rotatably mounted in the replacement modules for engaging the threaded pin and an extending assembly is provided for extending the overall length of the nut to the front face of the replacement module. In this embodiment, the end effector 74 would incorporate a rotatably driven tool adapted to engage the extending assemblies of the latching nut so as to rotatably drive the latching nuts to engage or release the threaded latching pins. These and other modifications will be apparent to those skilled in the art. 

What I claim as my invention is:
 1. In a remote manipulator system in which a television camera is mounted at a free end of a manipulator arm to relay a target image to a monitor having image alignment markings thereon, the manipulator arm having an end effector located at the free end thereof for use in mounting and releasing a complementary component with respect to a support structure, the improvement of;(a) a target mounted at a site remote from said complementary component in a direct line of vision of said camera when said end effector is axially aligned with said complementary component and said complementary component is mounted on said support structure, said target being proportioned such that its image viewed at the monitor is coextensive with the image alignment markings of said monitor when said end effector is operably positioned to mount or release said complementary component with respect to its associated support structure.
 2. In a remote manipulator system in which a television camera is mounted at a free end of a manipulator arm to relay a target image to a monitor having image alignment markings thereon, a plurality of complementary components releasably mounted on a support structure, said components being selectively engageable by said end effector so as to be mounted on or released from said support structure, the improvement of;(a) a plurality of end effector alignment targets, at least one of said targets being associated with each complementary component, each target being disposed in a direct line of vision of said camera when said end effector is axially aligned with the coupling component which is associated with it, each target having a mounting site remote from its associated complementary component, each target being proportioned that its image viewed at the monitor is coextensive with the image alignment markings of the monitor when said end effector is operably positioned with respect to the complementary component associated with the target which is in the line of vision of the camera.
 3. In a remote manipulator system in which a television camera is mounted at a free end of a manipulator arm to relay a target image to a monitor having image alignment markings thereon, a plurality of complementary components releasably mounted on a support structure, said components being selectively engageable by said end effector so as to be mounted on or released from said support structure, the improvement of:(a) a plurality of end effector alignment targets, at least one of said targets being associated with each complementary component, each target being disposed in a direct line of vision of said camera when said end effector is axially aligned with the coupling component which is associated with it, each target having a mounting site remote from its associated complementary component, each target being proportioned such that its image viewed at the monitor is coextensive with the image alignment markings of the monitor when said end effector is operably positioned with respect to the complementary component associated with the target which is in the line of vision of the camera, said target mounting sites being located at at least two different distances from the focal point of the camera when said end effectors are operably located with respect to the complementary components associated therewith.
 4. In a remote manipulator system in which a television camera is mounted at a free end of a manipulator arm to relay a target image to a monitor having image alignment markings thereon, the manipulator arm having an end effector located at the free end thereof, the improvement of:(a) a complementary component releasably mounted on a support structure, said complementary component being adapted to be releasably secured to said end effector which axially aligned therewith, (b) a target mounted at a site on said support structure remote from said complementary component in a direct line of vision of said camera when said end effector is axially aligned with said complementary component and said complementary component is mounted on said support structure, said target being proportioned such that its image viewed at the monitor is coextensive with the image alignment markings of said monitor when said end effector is operably positioned to mount or release said complementary component with respect to its associated support structure.
 5. In a remote manipulator system in which a television camera is mounted at a free end of a manipulator arm to relay a target image to a monitor having image alignment markings thereon, the improvement of:(a) a support structure, (b) first and second components releasably mounted on said support structure, said first component being releasably engageable by said manipulator arm and said second component being releasably engageable by said first component, (c) first and second alignment targets located on said support structure remote from said first and second components, said first target being disposed in a direct line of vision of said camera when the free end of the manipulator arm is axially aligned with said first component and being proportioned such that its image, viewed at the monitor is coextensive with the image alignment markings of the monitor when the free end of the manipulator is operably located with respect to the first component to secure the first component to the manipulator arm, said second target being disposed in a direct line of vision of said camera when said first component is axially aligned with said first component, said second target being larger than said first target and proportioned to be coextensive with the imaging markings on the monitor when the first component is operably positioned with respect to the second component. 